Pump service manual for 1DX, 2DX, 3DX, 3DNX, 3SP ... - Cat Pumps

More documents

Recommendations

Info

All 1DX.MIST, 2DX, 2DX.MIST and 3DX Models Discharge and Inlet Valve Assembly - Stacked Valve design SERVICING THE VALVES Disassembly NOTE: All pump models require one (1) stacked valve kit to repair pump. Models 2DX, 2DX.MIST, 3DX, 3DNX, 3SP and 3SPX contain three complete valve assemblies (inlet and discharge). Whereas, model 1DX03ELS.MIST contains two complete valve assemblies and model 1DX015ELS.MIST contains one complete valve assembly. NOTE: Discharge and inlet valve assemblies may stay together or separate during removal. NOTE: Spring retainer may also separate from the seat during removal. 1. Models 1DX.MIST, 2DX, 2DX.MIST and 3DX: Use a M19 Hex tool to remove valve plugs on top of manifold. Models 3DNX, 3SP and 3SPX: Use a M24 Hex tool to remove valve plugs on top of manifold. 2. Use a reverse pliers to remove stacked valve assemblies from the valve chamber. 3. If the discharge valve assembly separates from the inlet valve assembly, use a reverse pliers to remove it from the valve chamber. CAUTION: Exercise caution as the reverse pliers may damage the threads in valve chamber or spring retainer. 4. Models 1DX.MIST, 2DX, 2DX.MIST and 3DX: The spring retainer may separate from the seat. Remove the spring and valve from the valve chamber. Thread an M8 screw into the seat and remove from valve chamber. 5. Models 1DX.MIST, 2DX, 2DX.MIST and 3DX: Separate valve assembly by using the same M8 screw and thread into bottom of seat until screw contacts bottom of valve. Continue threading in screw until spring retainer separates from seat. Models 3DNX, 3SP and 3SPX: Separate valve assembly by inserting screwdriver into spring retainer and press the backside of valve until seat separates from the spring retainer. 6. Remove o-ring from each seat and valve plug. 3SP30G1I, 3SP35GEI, 3SPX30G1I, 3SPX35GEI Discharge and Inlet Valve Assembly - Stacked Valve design CAUTION: Before commencing with service, shut off drive (electric motor, gas or diesel engine) and turn off water supply to pump. Relieve all discharge line pressure by triggering gun or opening valve in discharge line. After servicing is completed, turn on water supply to pump, start drive, reset pressure regulating device and secondary valve, read system pressure on the gauge at the pump head. Check for any leaks, vibration or pressure fluctuations and resume operation. Inspect and service all system accessories on the same schedule as your pump. Reassembly 1. Examine spring retainers for internal wear or breaks in the structure and replace as needed. 2. Examine springs for fatigue or breaks and replace as needed. 3. Examine valves and seats for grooves, pitting or wear and replace as needed. 4. Examine seat and valve plug o-rings for cuts or wear and replace as needed. NOTE: Inlet valve seat and o-ring are different from discharge valve seat and o-ring. One valve kit required per pump. 5. Models 1DX.MIST, 2DX, 2DX.MIST and 3DX: Lubricate and install new o-ring onto large outside diameter of discharge seat. Models 3DNX, 3SP and 3SPX: Lubricate and install backup-ring, and then o-ring onto large outside diameter of discharge seat. 6. Place seat on work surface with small diameter side up. 7. Place valve onto seat with concave side down. 8. Place spring on valve. 9. Install spring retainer with deep stepped end over spring and snap onto seat. NOTE: Repeat steps 6-9 for inlet valve assembly. 10. Snap discharge valve assembly onto the inlet valve assembly and press into valve chamber until completely seated. 11. Lubricate and install new o-ring onto each valve plug. 12. Apply Loctite® 242® to threads of each valve plug and thread in hand tight. Torque to specifications per chart.
All 1DX.MIST, 2DX, 2DX.MIST and 3DX Models Lo-Pressure and Hi-Pressure Seals with Seal Case SERVICING THE SEALS Disassembly NOTE: All pump models require one (1) seal kit to repair pump. Models 2DX, 2DX.MIST, 3DX, 3DNX, 3SP and 3SPX contain (3) high pressure seals, (3) low pressure seals, (3) seal washers and (3) o-rings. Whereas, model 1DX03ELS.MIST contains (2) high pressure seals, (2) low pressure seals, (2) seal washers and (2) o-rings. The model 1DX015ELS.MIST contains (1) high pressure seal, (1) low pressure seal, (1) seal washer and (1) o-ring. 1. Using an M5 allen wrench, remove the hex socket head (HSH) screws from the face of the manifold head. 2. Insert flat head screwdrivers on each side between the crankcase and manifold head. Gently apply pressure to the head to begin separation. 3. Support the manifold head from the underside and pull the manifold head away from the crankcase. CAUTION: Keep the manifold head properly aligned with the ceramic plungers when removing to avoid damage to the plungers. NOTE: The seal case may stay in the manifold or on the ceramic plungers. 4. Place manifold head on work surface with crankcase side up. 5. Remove seal retainer from each plunger rod. 6. Use a screwdriver to pry out the Lo-Pressure seal from each seal case. CAUTION: Screwdriver may damage seal during removal. 7. Use reverse pliers to remove seal case from each seal chamber. NOTE: Insert the reverse pliers into the second lip to avoid damage to the seal case. 8. Carefully insert a small screwdriver under the o-ring and roll the o-ring off each seal case. CAUTION: Exercise caution as the screwdriver may score o-ring sealing surface. 9. Models 1DX.MIST, 2DX, 2DX.MIST and 3DX: The Hi- Pressure seals can be easily removed from each seal chamber by hand or with reverse pliers. Models 3DNX, 3SP and 3SPX: Remove V-Packing and male adapter from each seal chamber by hand or with a reverse pliers. 3SP30G1I, 3SP35GEI, 3SPX30G1I, 3SPX35G1I Lo-Pressure Seal, V-Packing, Male Adapter and Seal Case Reassembly 1. Examine the manifold chamber walls for scale buildup or damage. 2. Examine Hi-Pressure seals or V-Packings for frayed edges or uneven wear and replace as needed. 3. Examine seal case o-rings for cuts or deterioration and replace as needed. 4. Examine Lo-Pressure seals for wear to the internal ridges, outer surfaces for broken springs and replace as needed. NOTE: Seals and o-rings are available in seal kits. 5 Examine seal retainers for deformation and replace as needed. 6. Models 1DX.MIST, 2DX, 2DX.MIST and 3DX: Lubricate and install new Hi-Pressure seal by hand into each seal chamber with the grooved side down. Models 3DNX, 3SP and 3SPX: Install male adapter with notch side down. Lubricate and install new V-Packing by hand into seal chamber with grooved side down. 7. Lubricate and install o-ring on each seal case. Press small end of seal case into each seal chamber. 8. Press new Lo-Pressure seal into each seal case with the garter spring down. 9. Examine ceramic plunger for cracks or scale buildup and proceed to SERVICING THE PLUNGERS if worn. 10. Models 1DX.MIST, 2DX, 2DX.MIST and 3DX: Slide seal retainer over each ceramic plunger with the drain slots facing the crankcase and the openings to the top and bottom. Press into the crankcase. Models 3DNX, 3SP and 3SPX: Slide seal retainer over each ceramic plunger with the tabs facing out. Press into the crankcase. 11. Rotate crankshaft by hand so the two outside plungers are extended equally. 12. Lightly lubricate ceramic plungers, then carefully slide the manifold head over the ceramic plungers, supporting it from the underside to avoid damage to the plungers or seals. Press the manifold head up to the crankcase until flush. 13. Thread HSH screws in hand tight. Torque in sequence to specifications in torque chart.
Page 1: 1DX, 2DX, 3DX, 3DNX, 3SP, 3SPX PLUN
Page 5 and 6: SERVICING THE UNLOADER AND REGULATO
Page 7 and 8: Water* Flow Gal/Min HOSE FRICTION L

Pump service manual for 1DX, 2DX, 3DX, 3DNX, 3SP ... - Cat Pumps

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?